Modular and adjustable return air plenum for hvac systems

Abstract

A modular return air plenum for HVAC systems is provided that can be used to support a base an air handler unit or furnace in an HVAC system. The modular return air plenum is customizable in its width due to the use of one or more corner pieces, that when coupled together, form a connected return air plenum that is modular and adjustable in size. The modular return air plenum may include additional modular pieces that are integrated between the corner pieces. More than one modular return air plenum can be formed together and then stacked onto each other in order to increase a height of the combined modular return air plenum and provide for a taller modular return air plenum to best suit the support base needed for an air handler unit or furnace in the HVAC system.

What is claimed is: 
     
         1 . A system for a modular return air plenum for HVAC systems, comprising:
 a base, the base comprising:
 one or more base corner pieces, wherein the one or more base corner pieces are L-shaped, and include a first base corner piece that is generally perpendicularly oriented to a second base corner piece; and 
 one or more base modular pieces wherein the one or more base modular pieces are configured to connect to another base corner piece or to a base modular piece, 
 wherein each base corner piece of the one or more base corner pieces and each base modular piece of the one or more base modular pieces each have a first mating end and a second mating end, 
 wherein the first mating end of each base corner piece is configured to mate with the second mating end of another base corner piece or with the second mating end of another base modular piece, 
 wherein when the one or more base corner pieces are connected in a rectangular or square like arrangement with each other and/or with any base modular pieces, the base of the modular return air plenum is formed, 
 wherein the formed base of the modular return air plenum comprises a base interior cavity; and 
   a cap placed over a top surface of the base, the cap comprising:
 one or more cap corner pieces, wherein the one or more cap corner pieces are L-shaped, and include a first cap piece that is generally perpendicularly oriented to a second cap piece; and 
 one or more cap modular pieces wherein the one or more cap modular pieces are configured to connect to another cap corner piece or to another cap modular piece, 
 wherein each cap corner piece of the one or more cap corner pieces and each cap modular piece of the one or more cap modular pieces each have a first mating end and a second mating end, 
 wherein the first mating end of each cap corner piece is configured to mate with the second mating end of another cap corner piece or with the second mating end of another cap modular piece, 
 wherein when the one or more cap corner pieces are connected in a rectangular or square like arrangement with each other and/or with any cap modular pieces, the cap of the modular return air plenum is formed, 
 wherein the formed cap of the modular return air plenum comprises a cap interior cavity; 
   wherein the modular return air plenum comprises the formed cap removably attached to the top surface of the formed base,   wherein a width and a length of the modular return air plenum is customizable to suit and support an HVAC unit.   
     
     
         2 . The system of  claim 1 , wherein each assembled modular return air plenum is stackable onto another assembled modular return air plenum when additional height is required to suit and support the HVAC unit. 
     
     
         3 . The system of  claim 1 , wherein the modular return air plenum is configured to support an air handler unit or a furnace in an HVAC system. 
     
     
         4 . The system of  claim 1 , wherein each top surface of each base corner piece comprises a boss or a protruding piece that is configured to fit within a hollow underside of the cap. 
     
     
         5 . The system of  claim 1 , wherein each base corner piece comprises a longer side that is perpendicular to a shorter side. 
     
     
         6 . The system of  claim 5 , wherein an end piece of the longer side comprises a protruding bar like member, wherein the end piece of the longer side is the first mating end. 
     
     
         7 . The system of  claim 7 , wherein an end piece of the shorter side comprises a slot configured to receive the protruding bar like member in order to mate with either a base modular piece of the one or more base modular pieces or to mate with another base corner piece, wherein the end piece of the shorter side is the second mating end. 
     
     
         8 . The system of  claim 1 , wherein an interior of each base corner piece is hollow with a number of vertically aligned partitions having spaces between each vertically aligned partition. 
     
     
         9 . The system of  claim 1 , wherein the second mating end is configured to tightly mate with the first second mating end by press fit or friction fit. 
     
     
         10 . A modular return air plenum, comprising:
 one or more base corner pieces, wherein the one or more base corner pieces are L-shaped, and include a first base corner piece that is generally perpendicularly oriented to a second base corner piece; and   one or more base modular pieces wherein the one or more base modular pieces are configured to connect to another base corner piece or to a base modular piece of the one or more base modular pieces,   wherein each base corner piece of the one or more base corner pieces and each base modular piece of the one or more base modular pieces each have a first mating end and a second mating end,   wherein the first mating end of each base corner piece is configured to mate with the second mating end of another base corner piece or with the second mating end of another base modular piece,   wherein when the one or more base corner pieces are connected in a rectangular or square like arrangement with each other and/or with any base modular pieces, the modular return air plenum is formed,   wherein a width and length of the modular return air plenum is customizable to suit and support a size of an HVAC unit.   
     
     
         11 . The modular return air plenum of  claim 10 , wherein the modular return air plenum comprises an interior cavity. 
     
     
         12 . The modular return air plenum of  claim 10 , wherein multiple assembled modular return air plenums are stackable onto each other when additional height is required to suit and support the HVAC unit. 
     
     
         13 . The modular return air plenum of  claim 10 , wherein the modular return air plenum is configured to support an air handler unit. 
     
     
         14 . The modular return air plenum of  claim 10 , wherein the modular return air plenum is configured to support a furnace in an HVAC system. 
     
     
         15 . The modular return air plenum of  claim 10 , wherein each top surface of each base corner piece comprises a boss or a protruding piece. 
     
     
         16 . The modular return air plenum of  claim 10 , wherein each base corner piece comprises a longer side that is perpendicular to a shorter side. 
     
     
         17 . The modular return air plenum of  claim 16 , wherein an end piece of the longer side comprises a protruding bar like member, wherein the end piece of the longer side is the first mating end. 
     
     
         18 . The modular return air plenum of  claim 17 , wherein an end piece of the shorter side comprises a slot configured to receive the protruding bar like member in order to mate with either a base modular piece of the one or more base modular pieces or to mate with another base corner piece, wherein the end piece of the shorter side is the second mating end. 
     
     
         19 . The modular return air plenum of  claim 10 , wherein an interior of each base corner piece is hollow with a number of vertically aligned partitions having spaces between each vertically aligned partition. 
     
     
         20 . The modular return air plenum of  claim 10 , wherein the second mating end is configured to tightly mate with the first second mating end by press fit or friction fit.